Senior Mechanical Engineer, FEA Analyst

Are you ready to build America’s energy future? Form Energy is an American manufacturing and energy technology company. We’re revolutionizing energy storage with cost-effective, multi-day technology designed to keep the electric grid secure and reliable, even during extended periods of stress. By strengthening the electric system and reimagining what’s possible, we’re giving clean energy a whole new form! In recent years, Form Energy has earned a number of accolades, including being named by TIME as a “Best Invention”, MIT Technology Review as a “Top Climate Tech Company To Watch”, and Fast Company as “One of the Next Big Things In Tech”. We are making rapid progress on our mission of delivering energy storage for a better world, and our team is growing just as rapidly to meet demand. We have signed contracts with leading electric utilities across the United States and production of our iron-air batteries is underway at our first high-volume manufacturing facility in West Virginia. Working for Form Energy is more than just a job, it’s a chance to be part of something extraordinary. And now - right as we significantly scale up battery manufacturing - might be the most exciting moment in the company’s history to join. We are assembling a team of highly talented and driven individuals across the country. Driven by our core values of humanity, excellence, and creativity, our team is determined to deliver on our mission and transform the energy landscape for the better. Feeling energized to make a meaningful impact on the world? Then keep reading - you’ve come to the right place. Role Description The Mechanical Engineering team at Form is focused on designing the battery cell, module, and system enclosure that forms the foundation of our innovative utility-scale multi-day energy storage system. We strive to deliver designs that are optimized for performance, quality, reliability, and cost for high-volume manufacturing at Form Factory. We're hiring an experienced Senior Mechanical Engineer, FEA Analyst to join our Mechanical Simulation & Analysis team. This role is intensely focused on executing advanced structural and thermal finite element analysis (FEA) and model validation to proactively ensure our designs are performant, robust, and optimally meet requirements. You will work closely with cross-functional partners such as mechanical design, electrical engineering, cell performance, and system modeling to develop cohesive system architectures. As a key individual contributor, you will drive critical analysis in support of design and build activities on pilot manufacturing lines in Berkeley, CA, and production lines in Weirton, WV. If this sounds like the right role for you, apply now! This role will be located in our CA offices. This is an exciting opportunity to be part of scaling our multi-day energy storage system at Form and contributing to a sustainable future! Relocation assistance is available. What you'll do: Drive Advanced Simulation: Lead the structural and thermal finite element analysis (FEA) and optimization of Form Energy’s iron-air battery components, modules, and massive system enclosures. Build High-Fidelity Models: Develop, refine, and maintain complex FEA models (static, dynamic, non-linear, and thermal-structural coupled) to guide design decisions and solve difficult mechanical challenges. Correlate & Validate: Execute hands-on model validation and correlation by collaborating with test engineers to design physical tests and interpret empirical data to ensure analytical accuracy. Cross-Functional Collaboration: Partner directly with interdisciplinary teams of battery, electrical, chemical, systems, and reliability engineers to optimize designs for performance, cost, and reliability throughout the full development cycle. Influence Design: Participate in design reviews, translating complex FEA results into clear, actionable design recommendations for the broader engineering team. What you'll bring: Bachelor's Degree in Mechanical Engineering or related field; with 8+ years of industry experience focused specifically on mechanical simulation and analysis. Expert-level knowledge and hands-on capability in structural FEA (static/dynamic, linear/non-linear, fatigue, shock/vibe) and thermal FEA using industry-standard tools (e.g., ANSYS, Abaqus, Nastran). Well-developed experience analyzing mechanical systems, heavy assemblies, and components built for high-volume manufacture in a hardware product development company. Proven track record of hands-on experience in FEA model validation and correlation with physical test data. Solid foundation in mechanical design principles, defining engineering requirements, and implementing FMEA principles. Experience in batteries, energy storage, structural enclosures, or other high-power industrial products is a strong plus. Excellent technical communication skills, especially the ability to distill complex simulation data into digestible insights for non-analyst partners and cross-functional teams. Experience in structural optimization such as performing topology, topography, shape, and sizing optimization to minimize weight while maximizing structural stiffness and durability would be advantageous. #LI-Onsite Humanity is a cornerstone of Form Energy’s culture, and we make sure our compensation and benefits reflect that. Form Energy offers competitive salaries, stock options, and a holistic benefits package to ensure all employees have what they need to thrive while working here. When it comes to you and your family’s health, we cover 100% of medical, dental, and vision premiums for full-time employees - and 80% of healthcare premiums for dependents. This starts from day one. We also offer at least 12 weeks of paid leave for new parents (up to 20 weeks for birthing parents), and generous vacation policies to give employees time to recharge when needed. To build America’s energy future, we need everyone at the table. We are proud to be an equal opportunity employer, and encourage candidates from all backgrounds to apply to our open jobs. If you may require reasonable accommodations to participate in our interview process, please contact [email protected]. Requests for accommodations will be treated with discretion. Form Energy is committed to maintaining the privacy of our applicants. Please be aware that we will never solicit sensitive personal information such as Social Security numbers or bank account details during the recruiting or hiring process.